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T H E K E YS TON EGROU P. CO. U K
DESIGNING TO MEET THE PART L CHALLENGE
Help is at hand when planning demands compliance with Part L
2013 and there could be advantages by engaging early with an
expert
BUILT AS DESIGNED
An innovative roof window is enabling architects to fight back
against the performance gap between designed and built
performance
W IN NING LIN E S
IG’s award winning Masonry Support systems helped this Glasgow
project win an award for urban regeneration
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Welcome to the first edition of Innovating Times, The Keystone
Group’s response to challenges affecting design and performance
within the construction industry.
As we go to print we are reflecting on the government’s most
recent white paper ‘Fixing
our broken housing market’ and how we can address the challenges
it presents. We are investing heavily in our new timber division
and in a range of innovative offsite solutions which will provide
answers to the well documented skills shortage and the housing
crisis.
Further challenges include carbon reduction and the need to
develop construction products with enhanced energy efficiency. Our
aim is to enable design professionals to meet and exceed both the
spirit of carbon reduction and the requirements of future
regulatory demands.
Everyone’s talking about offsite construction so we take a
snapshot of some architects’ views.
IG’s innovative offsite solutions are revolutionising the
delivery of masonry support and brickwork design.
The challenge to close the gap between designed andbuilt
performance is one that will be around for awhile and should
feature heavily within the R&D team of anybuilding material
manufacturer. It is important that the construction industry
delivers both the design qualityand build quality of the
architect’s vision, unhindered by an onsite shortage of skills or
labour.
This is a challenge for construction material producers, to
innovate and evolve simple-to-use products, which facilitate the
efficient delivery of that vision.
At The Keystone Group, we are addressing these challenges
through a process of continuous improvement,and we always welcome
feedback and engagement with architects to understand their views
and priorities.Even though recent events have shown we can’t
alwayscontrol the world around us, we believe that togetherwe can
make a lot of things better.
Sean Coyle
Chairman, Keystone Group
In an increasingly unpredictable world, we believe the best
response is to focus on innovation which enhances the way we work
and meets the challenges faced by the industry today.
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W E LCOM E
WHAT IS THE FUTURE OF OFFSITE?
We get an insight on the key issues affecting a practice which
services some of the UK’s biggest house builders.
How The Keystone Group are innovating in a move towards ‘fixing
our broken housing market’.
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PRACTICE IN PROFILE
ACTIONS...NOT WORDS!
NO LIMITS TO DESIGN CREATIVITY
DIGI TA LCON T E N T
W IN NING LIN E S
A new Lintel turns out to be an unexpected carbon warrior. Find
out how.
26INNOVATIVE CARBON REDUCTION
C ON T E N T S
Take inspiration from a remarkable architect who keeps rising to
new challenges.
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NO ORDINARY ARCHITECT
DESIGNING TO MEET THE PART L CHALLENGEWhen planning demands
compliance with Part L 2013 help is at hand. There could be
advantages with expert engagement early in the process.
14INDULGE IN DETAILAn innovative brick detailing product opens
new doors for architectural design.
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E V E RY DAY OF F SI T EWe look at some popular offsite
options.
30S T R E NG T H IN N U M BE R S
Discover the full range of technical support and advisory
services available from The Keystone Group’s extensive technical
team.
Share a digital version of the publication and download full
digital product information from the Innovating Times web hub.
keystonegroup.co.uk/innovating-times
IG’s award winning Masonry Support systems helped this Glasgow
project win an award for urban regeneration.
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An innovative roof window is enabling architects to fight back
against the performance gap between designed and built
performance.
BUILT AS DESIGNED
NI / ROI SALES & SERVICE
Ballyreagh Industrial Estate
Cookstown, Co. Tyrone
BT80 9DG
T 028 8676 2184
F 028 8676 1011
[email protected]
GB SALES & SERVICE
Ryder Close, Cadley Hill
Industrial Estate, Swadlincote
South Derbyshire DE11 9EU
T 01283 200 150
F 01283 223 352
[email protected]
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Clear Architecture
James Mors
Associate Director
Clear Architecture
Control of costs, design, quality and safety of workforce are
all key elements that make this procurement route most attractive.
We often specify SIP panels for the superstructure of our projects
and we believe it to be very successful in terms of procurement and
the end product.
PRP Architects
Scott Sanderson
Director
PRP Architects
Offsite simply has to be an integral part of the industry
response to the continuing, chronic shortfall in housing supply and
our ambitions to improve quality, safety and performance.
We see two clear streams emerging. First, there is increasing
interest and confidence in the deployment of fully volumetric
housing systems, albeit in the short term volume will be relatively
limited, whilst system detailing and consumer confidence become
better established and manufacturing capability builds.
Secondly, there is welcome and increasing focus on a component
driven approach. This is based on building confidence to specify
early to secure quality, deeper and earlier connections with the
Tier 2 & 3 supply chain and a push to deliver downstream asset
management information using BIM.
Armstrong Burton Architects
Derek Burton
Director
Armstrong Burton
Architects
I think we’re all aware that we have a skills shortage problem
and I think the only way that this can be resolved, apart from
training more people, is to make construction easier - offsite
solutions are the answer to this. Offsite will continually evolve
due to this diminishing availability of skilled and unskilled
labour, the need for improved speed of erection whilst maintaining
quality and consistency and to meet future regulation. I think it
comes back to health and safety also, we do need to be more and
more conscious of health and safety concerns and offsite solutions
can deliver that security.
Angel Architecture
Kim Sankey
Historic Building Architect
Angel Architecture Ltd
I am often asked to design contemporary extensions to listed
buildings. This is where offsite construction and modular building
can come into its own, not least with the speed and efficiency it
delivers, but also avoiding months of waiting for individual
products, particularly bricks and windows, which often require a
long lead in time. I generally prefer a timber frame option in
these cases as they go up quicker and, having regard to CDM,
involve less risk than steel and masonry options. I would be keen
to learn more about modular building since it could revolutionise
the way we build and combat the housing shortage for example.
IN DUS T RY COM M E N TV OX P OP
FUTUREWhat is the
of offsite?We asked some architects where they see the future of
offsite
he offsite construction sector accounts for an
estimated 7% of total construction output in the
UK, worth over £1.5bn to the economy. Offsite
technologies now have the potential to address some of
the most persistent challenges facing the industry,
including
severe skill shortages and the drive to eradicate risks
to workers’ health and safety onsite.
The debate is now raging in the housing sector, where
the Government’s plan to build two million new homes
by 2020 is thought to be unachievable without a rapid
switch towards alternative construction methods.
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Technical Helpline
01283 200 157igmasonrysupport.com
No limits to design creativity
Description
Stonebridge Park’s £16.6 million development has created an
entirely new neighbourhood, producing 117 new homes in the area.
Modelled in three different types of accommodation, each apartment
building exhibits distinct and diverse characteristics. These
prominent structures would require a range of IG’s prefabricated
solutions.
Solution
Constructing the corbelled brick detail required a welded brick
slip masonry support solution. Produced offsite and delivered in 38
individual brick slip units, IG ensured the brick feature was
comprised of manageable components to facilitate optimum
adjustability. IG supplied installation drawings and a step by step
method statement to support the brickwork contractor onsite. An IG
engineer attended the site prior to and during the installation,
ensuring the prefabricated system was installed effectively,
achieving the desired facade.
Challenge
The Rotunda, a 9 storey, circular building, exhibits impressive
brick feature elements. The ground floor main entrance to the
Rotunda would require a 4.8m wide, 3.6m tall, 2m deep corbelled
brick feature.
IG had to accommodate the external wall radius of the
cylindrical structure, developing manageable brick slip units to
achieve this complex design. The soldier course detailing would
marry both onsite and offsite building methods, with the top course
of brick laid traditionally above each masonry support
installation.
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Products Used
Brick Slip Masonry Support
Architect
Cullinan Studio
Contractor
DurkanStonebridge Park Residential DevelopmentStonebridge Park,
LondonIG Masonry Support’s technical expertise allowed us to create
a single storey entrance appropriate to the scale of the 9 storey
Rotunda.
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Cullinan Studio
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The Challenge
The Laurieston project exhibits a refreshing, contemporary
alternative to the standard design of residential blocks. The
elegant courtyards and the exchange of typical bay windows for long
spanning balconies are all contributors towards the award winning
qualities of this regeneration project.
IG’s specialist team were appointed to supply Brick Slip Masonry
Support solutions. The technical challenges involved 327mm deep
brick soffits spanning over 8m as required for the recessed
balconies.
The Solution
IG Masonry Support combined bespoke Brick Slip Masonry Support
Systems and Brick Slip Lintels to ensure seamless and structural
brick clad soffits for all openings.
IG received a consignment of the bricks being used on the
project, which were then cut down to 25mm slips. The brick slips
were bonded to the patented steel system, which enabled the BBA
approved resin to mushroom through the perforations in the steel
and form a mechanical lock.
The revitalised contemporary homes offer a newfound vibrancy to
the community, whilst also ensuring the retention of clearly
defined blocks to reinforce the grid of the city.
The area has been revived with affordable high quality living, a
project that has since been awarded with the ‘The Best Urban
Regeneration Project’ at the prestigious Brick Awards.
IG’s Brick Slip Masonry Support Systems are one-piece
prefabricated units manufactured offsite and delivered to site
complete with bricks bonded to them. This system offers a major
reduction in onsite labour and installation time.
Description
The Laurieston development provided a significant opportunity
for transformation, regenerating part of central Glasgow.
The £22 million first phase development enriched the typical
residential block concept, incorporating more compelling
character.
Winning linesProducts Used
Brick Slip Masonry Support & Lintels
Architect
Elder Cannon / Page Park
Contractor
McTaggart ConstructionLaurieston Residential
DevelopmentLaurieston, Glasgow
The crisp lines of this award-winning project were facilitated
by an innovativemasonry support and soffit system.
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Technical Helpline
01283 200 157igmasonrysupport.com
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No ordinary architect
What drives you to success?
Doing what interests me ensures I enjoy whatever I am
doing and drives me to success. Also, a vital element for
me is being passionate about what I do. My lifelong passions
of mountaineering and architecture have expanded as
I have grown older, now extending to building restoration
and conservation work. Spending time in the mountains
exposes you to inspirational sights and vistas which spark
ideas for some interesting buildings.
How did you get started in architecture?
It was slightly accidental, my grandfather was a
professional
botanist and my father was an engineer. At the time of
choosing a career path, I decided on architecture as it was
a long course with lots of holidays so I could go climbing.
As soon as I started I realised I was fascinated, I enjoyed
the
work of local building conservationist Hugh Dixon who had
dedicated himself to recording important buildings at risk.
What still appeals about architecture?
I don’t think I will ever tire of the satisfaction that
comes
from designing something completely new or the buzz
of bringing a ruin back to life. It’s particularly appealing
to work on schemes breathing new life into old buildings
and I have been fortunate to have had the opportunity
to work on some really significant historic projects.
Few careers enable you to translate one’s vision into
practical reality but architecture is a daily challenge all
about visualising changes in advance and the process
of delivering those ideas into structures which meet
a complex set of user needs and regulatory demands.
Work needs to be motivating and our philosophy at
The Consarc Group is that every day we want to learn,
create and improve.
Innovating Times catches up with the remarkable Dawson Stelfox
MBE, whose achievements include the ascent of Everest, the
restoration of a parliament building and past Presidency of the
Royal Society of Ulster Architects.
hen you first meet Dawson Stelfox, Chairman of the Belfast based
Consarc Design Group, you are immediately impressed that this is a
man with
a mission and the determination to succeed. However, not with
the brashness of many high achievers, rather a more
understated style normally associated with strategists.
Undoubtedly, his greatest personal achievement was to become the
first person from Ireland to climb Mt Everest and the first from
Britain or Ireland to climb the North
Ridge, scene of Mallory and Irvine’s disappearance in 1924.
Since this epic achievement in 1993, Stelfox has continued
climbing but has also gone on to achieve much in his profession,
making a lasting impression on the built environment of his native
city Belfast and beyond.
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A R C HI T EC T IN FO C USIN T E R V IE W
W I T H
DAW S ON S T E LFOX
W HO IS DAW S ON S T E LFOX ?
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he Consarc Design Group works across the UK and Ireland on a
diverse
range of design projects including conservation and new build.
The specialists within the 45 person team deliver architectural
design, quantity surveying and project management.
Not many practices are in existence for the almost 100 years
that Consarc has been helping to define, shape and restore the
building fabric of Ireland and beyond. In its more recent past
Consarc Design Group has been at the helm of some of RIBA’s and the
RIAI’s award winning building projects including the Odyssey in
Belfast, Queen’s University and Parliament Buildings Stormont.
I actually enjoy all projects and probably my favourite will
always be whichever one I am working on at the time you ask as it
has the greatest intensity. However, I particularly enjoyed a
recently completed conservation project at The Graduate School at
Queen’s University Belfast.
This scheme involved the redevelopment of the former Library
Tower as a prestigious new home for the School of Law and a new
social hub as part of a £350m investment by the university,
developing world-class facilities for staff and students and
helping to attract new postgraduate students.
Another notable project in the past was the restoration of the
Parliament Buildings at Stormont, which is one of the greatest
architectural set pieces in Ireland. This was a big
conservation/restoration project after a disastrous fire destroyed
the original chamber. This restoration work brought the chamber
back to life and of course is now the seat of our devolved
government.
What have been your biggest challenges in life?
The biggest challenge in my life professionally was guiding the
company through the difficult times of the 2007 recession. The
crash in Ireland was much deeper and longer than the UK’s and was
fatal for many architectural practises along with every other part
of the industry. However, at a time when construction work was
dramatically slashed, we managed to become more efficient and came
through to become the company
we are today.
Personally, the Everest Expedition 24 years ago was a huge
personal challenge. In 1993, after years of planning, I became the
first person from Ireland to climb Everest and the first from
Britain or Ireland to climb the North Ridge, which was the scene of
Mallory and Irvine’s disappearance in 1924. I climbed Everest with
an amazing team who I still climb with regularly and we have gone
on to complete numerous other mountaineering expeditions.
What is your attraction to brick and what do you feel it adds to
a project?
I like the scale of brick and the way it adds texture, it is a
very traditional method of construction and defines the colour and
impact of a building. One of the great benefits of brick is that it
enables you to build a variety of complex features and decoration.
It also lends itself well to seamless repairs and the distinction
between old and new extensions to a listed building, something
which I value highly
as a conservationist.
Do you prefer new build projects or restoration /conservation
work?
I enjoy both, but I get enormous satisfaction out of taking
buildings that have been left abandoned and derelict and bringing
them back to life. There is great pleasure in working on pure
conservation work such as historic buildings, giving them a new
lease of life and seeing new
generations enjoy them.
You are clearly inspirational, do you have any words of wisdom
for us?
My key advice is that you need to be interested and passionate
in everything you do. You will only succeed if you put your heart
and soul into it. Passion and interest help to contribute to change
and always make room for adventure.
Consarc Design Group
Tell us about some of your favourite projects
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A R C HI T EC T IN FO C USIN T E R V IE W
P ROF ILE
Everday we want to learn, create and improve.
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Technical Helpline
01633 486 486iglintels.com
F IN D OU T MOR E
Technical Helpline
01283 200 150keystonelintels.com
Solution
Keystone’s Brick Feature Lintels offered an offsite solution
which would achieve the decorative elements across the dwelling’s
exterior façade. Manufactured bespoke to order these brick feature
components included a 2.4m span corbelled arch which defined the
porched entrance to the property. This single piece unit saved
Ascent Building significant installation time.
The level of quality control which could be achieved with these
products was a major advantage for the architect as all the brick
cutting and bonding took place in a controlled environment, free
from wet weather, extreme temperature and excessive dust. Keystone
collected a consignment of the brick being used on site and the
brick feature units were delivered to site with bricks bonded,
ready for installation and final pointing, ensuring that the arch
blended seamlessly with already constructed brickwork.
Keystone also supplied a range of other brick feature components
including flat gauge arches, full arch lintels and bullseye
lintels, all of which were manufactured bespoke to create the
elaborate brick features on this stunning home.
Indulge in detail
his comes as brick continues its resurgence in British
architecture, and while this trend may have been
restricted by skills shortages on sites the investment in
innovation by Keystone is removing that barrier.
These completely bespoke Keyslip products are used frequently in
refurbishment or new build ‘heritage’ projects. However the same
process can also be used to deliver contemporary brick detailing.
Keystone combines its outstanding structural expertise with its
patented brick slip adhesion system to produce incredibly effective
brick detail.
Each Keyslip unit is produced offsite in factory controlled
conditions using exactly the same brick from the main project. By
specifying the Keyslip system, architects are able to view CAD
drawings of the brick elements prior to manufacture which gives a
greater degree of certainty for the visual quality compared to
brick work built onsite.
This recent projects demonstrate the quality that is achieved
when adopting the Keyslip system.
Innovation in materials and manufacturing is enabling architects
to indulge in brick detailing with confidence. Keyslip Brick
Feature Lintels provide an effective means to achieving even the
most complex brickwork designs.
Products Used
Brick Slip Feature Lintels
Private Dwelling
Whyte Gates
Architect
Stephen Langer Architects Ltd
Contractor
Ascent Building LtdWhyte Gates
Description
Whyte Gates is an elegant 6 bedroom, 3 storey property,
exhibiting features reminiscent of the arts and crafts movement.
This project was a replacement dwelling constructed with high
quality materials and significant attention to detail throughout.
The original family home was demolished, providing a blank canvas
for Stephen Langer Architects.
Challenge
Ascent Building Ltd were assigned with delivering the
architect’s vision. The intricate brick detailing required around
the openings would require a great deal of skilled labour and brick
cutting onsite if constructed using traditional methods. This would
have been a time consuming task and required a high level of
accuracy to ensure consistency across the brickwork.
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Keystone’s patented design enables
BBA certified adhesive to interact
with a perforated steel backing plate
to form a strong mechanical bond with
the brick slips. Like many of the most
innovative ideas this concept is
incredibly simple but has proved to
be highly effective and reliable.
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Perforated design allows the adhesive
to pass through the steelwork
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Brick slips are bedded in a high
performance BBA approved adhesive
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The adhesive ‘mushrooms’ to form a
mechanical lock on the inner side of the steel
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Practice in profile
urrently, there would appear to be a major drive by the
industry, which is aligned with the Government’s
2020 ambitious targets and its thinking on the need for more
offsite solutions to provide the housing stock required for the
country.
We have to improve the housing numbers across the country,
everybody knows that, it’s in the news almost every week, and we
have skills shortages and time scale issues. If offsitecan assist
that then it is the way the industry will want to go. As far as we
are concerned, we want to be at the forefront of this in advising
and delivering alternative architectural solutions for our
clients.
I think in the industry press we have certainly seen more
commentary on offsite and frequently more positive attitudes
towards alternative methods and the benefits these can bring.
Undoubtedly we now have more clients keen to consider modern
methods such as modular construction, pods and alternative
construction approaches including timber and steel frames. House
builders will talk to us more and more about these alternative
options before they make a decision on which way they want to
go.
Is offsite the big story of 2017?
Architect Derek Burton shares his views from a busy practice
with a special focus on housing design for developers and house
builders.
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FO C US ON HOUSINGIN T E R V IE W
W I T H
DE R E K BU R TON
We need offsite producers to invest in efficient support.
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What’s driving the interest in offsite?
I think it is a combination of factors. Undoubtedly it’s the
desire to reduce personnel onsite, not having the skills onsite,
wanting to build more quickly. Builders also want to improve health
and safety and they know that offsite has a reputation for reducing
risk. If there wasn’t a cost benefit at the end of it then clients
maybe wouldn’t consider it - so I would probably say that it’s
costs and health and safety because I know these are major concerns
for a number of clients.
Have you found it easy to engage with offsite?
For most factory built elements we are relying on the supplier
to provide detailed drawings and specifications because each
project is different and manufactured to order. So assuming that
the offsite supplier is efficient then it should be a simple and
straightforward process for our team to incorporate their details
into our drawing packages.
On this basis it shouldn’t be a problem for architects to
accelerate their adoption of offsite but we will certainly need the
offsite producers to invest in efficient support if the process is
to run smoothly. We find that the producer’s technical advisors
clearly know their systems inside out. However, sometimes they
forget that customers will not be so familiar and may need more
basic assistance.
Give us your real world opinion of BIM?
I believe that it is widely recognised that BIM will become the
normal way of working just as the drawing board gave way to CAD. To
me it is inevitable that it will become the norm, the standard.
Clearly the advantages are already being shown on large complex
building projects and it is a government requirement on public
sector projects.
It has been more difficult to translate those benefits to
housebuilding but gradually more major housebuilders are either
implementing BIM or considering the options and timescales for its
introduction.
Although, in the first instance, this is used in development of
standard house types perhaps from a central design office and it
has yet to move out to the majority of regional offices.
A large part of this reluctance is the high capital investment
involved in putting the software into all of their regions and
there is also a training issue, as many people don’t yet have the
expertise within the internal design departments to fully implement
it.
Of course a large part of BIM is collaboration and house
builders are good at this with highly developed supply chains and
standardisation. Taylor Wimpey, for example, have provided a
service for the last 10 years where collaboration
has been a core function with their supply chain.
How has your practice developed recently?
We did a lot of work in 2016 involving the national space
standards. Obviously developing existing house builders’ house type
ranges and expanding those to have options for the national space
standards.
The opportunity arose to start working on our first large-scale
timber frame project. We always had clients expressing interest in
using timber frame or metal frame structures in the past but they
always went away from it at the last minute, whereas this project
was with a contractor who has a specialist timber frame division.
It is an interesting project - an Extra Care development of 70
apartments and supporting facilities.
More and more planning applications now need to be supported by
the use of 3D modelling and sketch up modelling so we decided to
expand our capabilities in this regard including housing layouts,
design and graphics.
What’s next for Armstrong Burton Architects?
We are rebranding for the first time in twenty years and along
with that will come a new website, a change of colour and a new
logo so it’s all very exciting but there’s a lot of work involved.
In terms of projects ahead we are looking at a new apartment range
for a national house builder - I think it gives an indication that
more apartments are being planned in addition to housing.
Our first full BIM project is also expected this year. We
haven’t actually been instructed on one but a number have clients
have indicated that their next project will be full BIM so this
will be a new departure for us. We do have six full BIM
workstations ready to go once we get that instruction.
In addition to mainstream house building we also specialise in
the retirement and Extra Care sectors for older people. The product
for this market is evolving with people living longer, both in
terms of lifestyle and care. I am hoping to be involved with the
development of these new products over the next twelve months or so
- it is very much my speciality.
Outside of that we are concentrating on business development,
expanding our work with national house builders and housing
associations. We aim to be more focused on this than perhaps we
have been in the past. We have been heavily reliant on repeat
business from clients, so we are trying to concentrate this year on
developing additional new relationships for example with other
regional offices of existing clients.
We’d also like to develop relationships with new house builders
and housing associations. We’ve not done so much work on the
commercial and industrial front since the recession so we would
like to initiate that as well. So its certainly looking like a busy
year!
What type of offsite systems are you currently specifying?
We have worked with Smartroof and other roof systems as well as
different construction solutions such as metal/timber frame and
panelised systems. Smartroof is an example of one offsite solution
which has worked exceptionally well because of its simplicity
onsite and it has proven to be an excellent choice for our clients,
so on this basis we are happy to specify it on appropriate
projects.
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D of Amstrong Burton Architects based in Sutton Coldfield, Derek
works with a number of the UK’s
leading house builders and is uniquely placed to provide an
insight into how trends are working through at the sharp end of the
industry.
FO C US ON HOUSINGIN T E R V IE W
W HO IS DE R E K BU R TON ?
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Everyday offsite
Offsite technologies come in different shapes and complexities
but these examples offer architects an easy opportunity to
experience many of the benefits.
ffsite is not being promoted as the answer to every situation
because, for some bespoke builds with a high degree of
personalisation,
factory built offsite solutions may not be cost effective. For
many architects however, new offsite options are delivering welcome
advantages for both the designer and the client.
The much reported skills shortage is a reality and while
complete factory built or modular houses are not yet appearing in
volume, the use of offsite components is now widespread.
A dormer window would be a good example of a labour intensive
task for a skilled joiner onsite and requires multiple trades to
construct and finish it. Compare that process to a factory built
dormer which can benefit from economies of scale and the process
can be quality managed at every stage of production. The process to
insulate the dormer in a factory environment for example is likely
to result in a far superior finish without voids or gaps which
could occur if insulated onsite leading in time to cold bridging
problems.
For the architect engaged on larger schemes this brings the
opportunity to engage with IG Elements to discuss the logistical
and performance benefits which offsite can bring. In addition to
these speed and quality benefits the industry also values the
contribution offsite makes by reducing onsite risks such as working
at height.
Architects can engage directly with the Wyckham Blackwell
technical team who will provide advice and a specialist design
service to achieve the required roof or floor detailing optimised
for each project.
W HO IS W YCK H A M BL A CK W E LL ?
Wyckham Blackwell is a structural timber specialist with fifty
years’ experience of design and manufacture. In 2016 they entered
into a strategic partnership with Keystone to develop new products
and offsite technologies.
imber trusses were perhaps some of the first modern offsite
products to be adopted. The factory built alternative
to an in-situ cut roof has introduced significant advantages to
the industry, firstly in terms of the computer aided structural
design which enables spans to be increased with less timber.
The latest generation of timber engineering includes CE
certified integrated metal webb floor and rafter solutions which
have the ability to eliminate steel beams from many projects.
Modern attic trusses can deliver huge benefits when it comes to
maximising living space within a roof.
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01283 552 205igelements.com
Technical Helpline
01675 442 233wyckhamblackwell.co.uk
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IG E LE M E N T S
IG Elements is at the forefront of the offsite manufacturing
sector and supply many of the UK’s leading house builders with a
range of factory built components.
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01283 200 199 smartroof.co.uk
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Actions...not words!
In advance of the launch of an offsite house, Commercial
Director, Sean Og Coyle explains what actions The Keystone Group
are taking to meet the challenges outlined in the Government’s
white paper ‘Fixing our broken housing market.’
“This country doesn’t have enough homes. That’s not a personal
opinion or a political calculation. It’s a simple fact.” Stark
words indeed from Sajid Javid, Secretary of State for Communities
and Local Government, but it is a reality with which the British
public are faced.
The Government’s determined focus on the need to address the
housing crisis has thrown down the gauntlet to the house building
industry. Ambitious targets, hampered by the lack of skills and
labour shortages, leaves every house builder in the country
considering how they can join the current “offsite” revolution in
our industry.
Of course none of this comes as a surprise to those of us in the
industry which is why The Keystone Group has progressively invested
in design and manufacturing capabilities to meet these
challenges.
e operate at the sharp end, working closely with house builders
to develop the innovative solutions which are most
likely to be adopted on the basis that they are commercially
sound and inherently practical.
Central to the themes of this latest white paper are the issues
of increasing the speed of construction and diversifying the
market. The government have given their commitment to exploring
innovation and to embracing modern methods of construction, citing
the many advantages this will bring to this broken industry:
The white paper reports “…homes constructed offsite can be built
up to 30% more quickly than traditional methods and with a
potential 25% reduction in costs. They are high quality, reliable,
more productive and can be highly efficient. They can require fewer
people onsite, helping to mitigate the skills shortage. Some firms
are increasing their use of these methods, but we need to go
further.”
Given the above assertions, we believe that the future supply of
housing will be met by either factory built modular homes or a more
versatile factory fabricated flat pack system. The Keystone Group’s
extensive product range covers all the major components needed to
deliver the latter and we are currently partnering developers in
delivering this solution.
The opportunity for architects is now to embrace the industry’s
change to modern methods of construction and consider how house
design might change to meet the challenges outlined in the white
paper while at the same time be optimised for offsite builds.
Creative architecture will play an important role in optimising
land use while enhancing the home owner’s living experience. To
achieve the density required in cities and social housing,
designers must develop new house types and address the external
landscape which forms the sense of place in communities. The white
paper makes it clear that change will have to occur across the
board if the future is not to be a repeat of the past.
“Keyhouse” draws on the expertise within our timber division
including our own roof truss company, our newly acquired timber
frame house company and market leading Smartroof. The reality is
that factory built homes can literally be installed onsite in days
rather than months. This dramatically reduces the pressures
currently associated with the skills shortage and the need for
multiple skilled trades onsite.
Our reputation in the industry is built upon our existing award
winning innovations across a range of offsite products. This track
record attracts interest amongst major developers and leads to
their engagement with our R&D team who get involved in their
strategic planning for new building methods.
We have recently engaged the services of Chris Hagan to
spearhead the Keyhouse project, therefore demonstrating our
commitment to this product. Chris’s experience at Space4, the
timber frame division of Persimmon Homes, will help us to serve the
market with a factory built house, maintaining the expertise and
customer care that customers have come to expect from The Keystone
Group.
Keystone’s track record in offsite to date has been strong. We
have focused on developing factory built housing components which
enable house builders to enjoy the key benefits of offsite. These
include build quality, enhanced energy efficiency and a reduction
of onsite risks to the health and safety of staff.
The opportunity for architects is now to embrace the industry’s
change to modern methods of construction.
We need to build many more houses, of the type people want to
live in, in the places they want to live.The Rt Hon Theresa May MP,
Prime Minister
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Innovating Times asks how?
irst and foremost, engagement with a good sustainability
consultant assists architects to maintain design freedom
and still meet the client’s needs for build efficiency.
Obviously this has to be achieved whilst still achieving compliance
with the requirements of the legislation and any additional
planning obligations relevant to the site.
By working in partnership with an energy assessor the designer
can add real value to their role in the eyes of the client by
assisting them to build schemes more cost effectively. This can be
a win win situation when this early intervention also helps the
architect to protect the integrity of their design in the finished
build.
Experienced assessors, such as AES, bring an added advantage due
to their in-depth knowledge of both the built environment and up to
date information on innovative products that, when viewed
holistically in relation to the whole house enable the architect to
create specifications resulting in reduced build costs.
In addition to the SAP assessments many good consultants will
identify early in the design process whether there is any potential
risk of overheating that can lead to health and wellbeing issues
for the occupants. The SAP assessment can indicate potential risk,
however, it is not an accurate assessment and in order to evaluate
the true risk, dynamic simulation would potentially be
required.
Through carrying out this additional level of analysis the risk
can be more accurately assessed and potential mitigation measures
proposed. These can involve design changes such as the introduction
of shading etc. which can be sensitively designed in at an early
stage. Through close liaison between the sustainability consultant,
client and architect, the most cost effective mitigation measures
can be agreed without threatening the design integrity of the
finished build or resulting in significant add-on costs to the
project.
How early in the designprocess do you recommend architects
should engage?
It is extremely important to engage as early as possible with a
good quality consultant, ideally at planning stage, to ensure that
the energy strategy can be developed to meet the site specific
requirements most cost effectively but most importantly, in such a
way that won’t threaten the original design on site.
Early engagement can also assess risks of overheating so that
any mitigation measures are incorporated early into the design,
avoiding any costly re-working of design or planning delays further
down the line. We can also help identify any conditions that are
open to challenge or offer advice on alternative approaches that
could be acceptable to the planners that, if successful, would lead
to significant cost savings for the developer.
What is your view on renewable technologies that rely on
serviceable items?
I’m always supportive of innovation, especially
if it leads to an energy demand reduction. Fabric
first is always the method we would advocate
initially because it delivers a benefit for the lifetime
of the property and it’s not reliant on mechanical
solutions that tend to have a far shorter lifespan.
Most technologies such as photo voltaic, solar
thermal, heat recovery systems etc. require some
level of maintenance in order to function efficiently
and will need replacing at some stage, meaning
further cost for the homeowner. In terms of
air quality, there’s a lot of innovation in this
market with heat recovery systems and
ventilation systems.
They definitely have a place, especially with the
way we are building much more thermally efficient
and air tight properties. Whilst this is positive on
one hand in terms of energy reduction, there’s a
risk we could be storing up problems for the future
in terms of air quality and the potential for
ill health in this country.
The other major issue is the risk of overheating
which is something that we deal with on a daily
basis. We advise clients on overheating risks,
helping the design team design in mitigation
measures. I know there’s a lot of discussion
regarding this within the industry and the
Zero Carbon Hub were focusing on this.
What part can innovative products like the Hi-therm lintel
play?
The way that we measure heat loss in any property has evolved
considerably over the last 10 years and one of the things that has
long been a problem is the heat losses through continuous linear
thermal bridges as opposed to repeated thermal bridges. However
this has been addressed in Part L and is now included in the way we
carry out assessments. Now we are looking at the majority of the
bridges between the construction elements and the two main areas
where heat loss occurs through that bridge would be floor junctions
and lintels. If you have a steel lintel that’s bridging the cavity
you’re going to have a significant amount of heat loss at that
junction. The Hi-therm lintel, in the way it has been designed and
manufactured, dramatically reduces that heat loss, so as a
standalone product I think it’s fantastic.
The Hi-therm lintel cannot on its own meet the requirements of
the overall property in terms of the heat loss calculation. It’s
part of a solution, whether it be lintels, construction elements,
insulation or boilers. They can all form part of the solution -
they aren’t the solution alone.
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S P OT LIGH T ON S US TA IN A BILI T YIN T E R V IE W
Sustainability expert Jon Bodington of AES claims architects
have a lot to gain by engaging with consultants early in the design
process.
Designing to meet the Part L challenge
W I T H
J ON BODING TON
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How can a lintel make so much impact?
Lintels over doors and windows account fora significant amount
of a building’s non-repeating thermal bridging and thereby
associated heatloss. By specifying the Hi-therm lintel it is
possible to reduce a dwelling’s thermal bridging by up to 30%,
which makes a significant contribution towards Part L
compliance.
Hi-therm’s innovative design incorporates a GRP thermal break
into a steel lintel. The structural performance and easy build
characteristics of a traditional lintel are retained but a dramatic
improvement in thermal efficiency is gained through the reduction
in thermal bridging.
What are the real benefits within SAP?
Because SAP is a cumulative calculation, the gains made by
reducing thermal bridging can deliver dividends in other areas,
benefiting the designer and developer alike. For example the
enhanced performance may negate the need for enlarged cavities,
giving more living space for the same exterior footprint. Other
benefits might include a reduction in the PV panels required and
while each design will differ, the use of Hi-therm has the
potential to deliver savings in the total build cost.
New Psi value calculator now available
While U-value calculators have been around for a while, The
Keystone Group has become the first lintel manufacturer to offer an
online Psi value calculator. Architects can now obtain a Psi value
for alternative wall specifications with just a few mouse clicks,
completely free of charge. These calculations are produced using
the certified Trisco software and the Hi-therm tool issues a
certificate for each detail.
Innovative carbon reduction
If you are designing new homes with a London zero carbon target
or just for
a site to comply with Part L 2013 regulations then the
innovative Hi-therm
lintel is an ideal place to start.
Keystone have produced an informative white paper which contains
a useful introduction to the issues surrounding energy efficiency
and Part L 2013.
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The BBA certified Hi-therm Lintel is up to 5 times more
thermally efficient than a standard steel lintel.
Previously this information was only available from specialist
energy companies typically costing between £200 - £400 per detail,
on a 7-10 day turnaround.
By using the Hi-therm tool, specifically calculated Psi values
for the lintels can be used within SAP helping to lower the thermal
bridging Y-value, assisting with Part L compliance.
You can access the Psi value calculator at
keystonelintels.com/hi-therm-lintel/
psi-value-calculator
iglintels.com/hi-therm-lintel/
psi-value-calculator
The call to combat thermal bridging
Thermal bridging and Psi values may not have been factors which
rated highly on your checklist previously but now they must be
addressed seriously. The latest regulations require this focus on
heat loss caused by thermal bridging at junctions which now impacts
on both the dwelling CO2 emission rate (DER) and fabric energy
efficiency rate (DFEE) which is calculated within SAP.
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S
The Hi-therm lintel is a highly effective solution to thermal
bridging
DO W N LO A D
Technical Helpline
01283 200 150keystonelintels.com
keystonelintels.com/downloads
Technical Helpline
01633 486 486iglintels.com
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Built asdesigned
espite raised energy efficiency standards in UK building
regulations, the gap between designed and built
performance remains a major challenge for the industry. Field
work carried out by Zero Carbon Hub prior to their demise uncovered
a 26% discrepancy in energy use between design stage SAP and what
was actually built. Thermal images from this study showed
significant heat loss around windows and doors, caused by poor
detailing, to be a major issue.
This point is particularly relevant when specifying roof windows
due to the fact that their installation requires an oversize
opening and therefore a physical gap around the perimeter of the
frame. Manufacturers do produce separate insulating collars to
close this gap but research has shown that up to 97% of all roof
windows from other manufacturers are not sold with a thermal
collar. This means that once these windows are installed, a void
could be left around the window, contributing to the performance
gap mentioned above.
The GAP if left unfilled can lead to:
– Lower U-value than stated by a roof window manufacturer–
Increased thermal bridging– Reduced airtightness
This poor detailing will result in increased energy use and will
also increase the risk of mould growth on surrounding surfaces
caused by thermal bridging and its resultant condensation.
It might be reasonable to think that problems with mould would
be long behind us in new build properties but ironically the
overall improvements in insulation and airtightness work to
accelerate the problem in situations where poor detailing creates
cold spots on internal surfaces.
Computer modelling confirms the risk of condensation forming on
the interior frames of uninsulated roof windows using typical
interior temperatures and humidity levels during winter when
external temperatures fall to zero.
Innovative Solution
The good news is that specifiers can now choose a roof window
that was designed to eradicate these problems. Keylite’s innovative
solution to the performance gap was to design and patent a unique
expanding thermal collar which is built into the roof window’s
frame at no extra cost. Once the window is fixed in position the
collar is activated simply by pulling a tape which causes the
collar to expand and close the gap.
This innovation highlights the value of architects working
closely with building material producers to find solutions to the
performance gap. While many products appear strong on paper, their
performance may be over reliant on complex detailing on site.
Keylite’s approach is to make it easier for builders to achieve
effective detailing without adding any additional barriers such as
added cost or specialist skills.
Naturally save energy
Incorporating roof windows into your design can also save energy
due to their efficiency as they can provide three times more
daylight than a vertical window of similar scale.
A study by the De Montfort University uncovered that 15%-20% of
floor area dedicated to rooflights reduces CO2 emissions. This can
be achieved with a combination of roof windows. The energy balance
for roof windows is generally better than the energy balance for
facade windows and all Keylite roof windows with standard Thermal
glazing provide a positive energy balance.
Exterior Aesthetics
Keylite’s innovative approach also extends to the visual quality
of the installation. To minimise the impact on exterior aesthetics
Keylite windows now have a recessed fit enabling them to sit 12mm
lower in the roof window as standard. Each of these enhancements
enable the specifier to take more control of the final performance
outcomes in a build which we understand is a welcome opportunity
inthe fight against the performance gap.
Innovations
A Keylite window closes the performance gap:
– Unique built-in expanding thermal collar incorporated at no
extra cost– Combats thermal bridging– Enhances U-values in the roof
opening– Combats Condensation and mould risk– Fabric first solution
delivers long term energy saving.
An innovative roof window from Keylite is helping specifiers to
close the gap between designed and built performance.
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The Performance Gap
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W S
Solar Gain(G-value)
Heat Loss(U-value)
Energy Balance+ =
28
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T EC H NI C A L S U P P OR T
With over 80 qualified technical engineers in our team we are
driven by innovation and are dedicatedto delivering industry
leading technical support.
ach Keystone Group company has a dedicated team of qualified
civil and structural engineers ready to assist
you at every stage of the construction process from design to
build. These professionals are on hand to discuss the most
appropriate product selection for your project and are renowned for
their ability to find creative solutions to technical challenges.
In particular they are focused on helping the architect to achieve
their design goals in the most technically efficient way.
Please refer to our Hotline numbers for the appropriate
technical team.
Lintels, Windposts & Brick Feature LintelsUK T 01283 200
150NI / ROI T 028 8676 2184
IG Masonry Support T 01283 200 157
Keylite Roof Windows T 01283 200 158
IG Elements T 01283 552 205
Smartroof T 01283 200 199
Wyckham Blackwell T 01675 442 233
Book CPD Seminars
Our current CPDs are available as follows:
KeyliteImproving natural daylight through
a range of innovative roof window solutions.
A best practice guide to optimising natural light and energy
efficiency.
Bookings can be made
onlinekeyliteroofwindows.com/cpd-booking
or by contacting us at T 01283 200 158
or email [email protected]
Keystone / IGA Fabric First approach
to sustainable construction.
Understanding the impact that lintel innovation can play in
improving the fabric energy efficiency of a building.
Bookings can be made by contacting T 01283 200 150
or email [email protected]
Strengthin numbers
View BIM Models
BIM models for our steel lintel range are available to download
on the IG and Keystone websites.
keystonelintels.com/bim-downloads/
iglintels.com/bim-downloads/
Calculate Psi Values
Our unique Psi Value Calculator enables you to print a
certificate for the Psi value of your chosen wall construction when
using Hi-therm lintels.
iglintels.com/hi-therm-lintel/
psi-value-calculator/
keystonelintels.com/hi-therm-lintel/
psi-value-calculator/
Download CAD Files
A range of Fasttrack CAD drawings are available for
download.
Lintelsfastrackcad.com/cad.asp?company_id=97
iglintels.com/technical-information/
cad-drawings/
Keylite Roof Windows keyliteroofwindows.com/architects/
downloads/cad-drawings
Download White Paper
Keystone have produced an informative white paper which contains
a useful introduction to the issues surrounding energy efficiency
and Part L 13.
keystonelintels.com/downloads
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Hi-therm, the single most cost efficient solution for
lowering
carbon emissions within SAP.
Remarkably advanced
Available from:
Psi value calculator available on: hi-thermlintels.com New
WINNERBEST BUILDING FABRIC PRODUCT 2013 & 2014
NATIONAL HOUSEBUILDER AWARDS
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